CH 27

CHAPTER 27
Fusion-Welding Processes
Kalpakjian • Schmid
Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 27-1
General Characteristics of Fusion Welding
Processes
TABLE 27.1
Skill level Welding Current Cost of
*
Joining process Operation Advantage required position type Distortion equipment
Shielded metal-arc Manual Portable and High All ac, dc 1 to 2 Low
flexible
Submerged arc Automatic High Low to Flat and ac, dc 1 to 2 Medium
deposition medium horizontal
Gas metal-arc Semiautomatic Most metals Low to All dc 2 to 3 Medium to
or automatic high high
Gas tungsten-arc Manual or Most metals Low to All ac, dc 2 to 3 Medium
automatic high
Flux-cored arc Semiautomatic High Low to All dc 1 to 3 Medium
or automatic deposition high
Oxyfuel Manual Portable and High All — 2 to 4 Low
flexible
Electron-beam, Semiautomatic Most metals Medium All — 3 to 5 High
Laser-beam or automatic to high
* 1, highest; 5, lowest.
Oxyacetylene Flames Used in Welding
Figure 27.1 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting
operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing, flame. The gas
mixture in (a) is basically equal volumes of oxygen and acetylene.
Torch Used in Oxyacetylene Welding
Figure 27.2 (a) General view of and
(b) cross-section of a torch used in
oxyacetylene welding. The acetylene
valve is opened first; the gas is lit
with a spark lighter or a pilot light;
then the oxygen valve is opened and
the flame adjusted. (c) Basic
equipment used in oxyfuel-gas
welding. To ensure correct
connections, all threads on acetylene
fittings are left-handed, whereas those
for oxygen are right-handed. Oxygen
regulators are usually painted green,
acetylene regulators red.
Pressure-Gas Welding
Figure 27.3 Schematic illustration of the pressure-gas welding process.
Shielded Metal-Arc Welding
Figure 27.4 Schematic illustration of the shielded

metal-arc welding process. About 50% of all
large-scale industrial welding operations use this
process.
Figure 27.5 Schematic illustration of the shielded

metal-arc welding operations (also known as stick
welding, because the electrode is in the shape of a
stick).
Multiple Pass Deep Weld
Figure 27.6 A deep weld showing

the buildup sequence of individual
weld beads.
Submerged-Arc Welding
Figure 27.7 Schematic illustration of the submerged-arc welding process and

equipment. The unfused flux is recovered and reused. Source: American Welding
Society.
Gas Metal-Arc Welding
Figure 27.8 Schematic

illustration of the gas metal-arc
welding process, formerly
known as MIG (for metal inert
gas) welding.
Equipment Used in Gas Metal-Arc Welding
Figure 27.9 Basic equipment

used in gas metal-arc welding
operations. Source: American
Welding Society.
Flux-Cored Arc-Welding
Figure 27.10 Schematic illustration of the flux-cored arc-welding process. This operation
is similar to gas metal-arc welding, showing in Fig. 27.8.
Electrogas Welding
Figure 27.11 Schematic illustration of the
electrogas welding process. Source: American
Welding Society.
Equipment for Electroslag Welding
Figure 27.12 Equipment used for
electroslag welding operations.
Source: American Welding Society.
Designations for Mild Steel Coated Electrodes
TABLE 27.2
The prefix “E” designates arc welding electrode.
The first two digits of four-digit numbers and the first three digits of five-digit numbers
indicate minimum tensile strength:
E60XX 60,000 psi minimum tensile strength
The next-to-last digit indicates position:

EXX1X All positions
EXX2X Flat position and horizontal fillets
The last two digits together indicate the type of covering and the current to be used.
The suffix (Example: EXXXX-A1) indicates the approximate alloy in the weld deposit:
—A1 0.5% Mo
—B1 0.5% Cr, 0.5% Mo
—B2 1.25% Cr, 0.5% Mo
—B3 2.25% Cr, 1% Mo
—B4 2% Cr, 0.5% Mo
—B5 0.5% Cr, 1% Mo
—C1 2.5% Ni
—C2 3.25% Ni
—C3 1% Ni, 0.35% Mo, 0.15% Cr
—D1 and D2 0.25–0.45% Mo, 1.75% Mn
—G 0.5% min. Ni, 0.3% min. Cr, 0.2% min. Mo, 0.1%min. V,
1% min. Mn (only one element required)
Gas Tungsten-Arc Welding
Figure 27.13 The gas tungsten-arc welding process,
formerly known as TIG (for tungsten inert gas) welding.
Figure 27.14 Equipment for gas tungsten-arc

welding operations. Source: American
Welding Society.
Plasma-Arc Welding
Figure 27.15 Two types of plasma-arc welding processes: (a)

transferred, (b) nontransferred. Deep and narrow welds can be made
by this process at high welding speeds.
Comparison of Laser-Beam and Tungsten-Arc
Welding
Figure 27.16
Comparison of the
size of weld beads in
(a) electron-beam or
laser-beam welding to
that in (b)
conventional
(tungsten-arc)
welding. Source:
American Welding
Society, Welding
Handbook (8th ed.),
1991.
Example of Laser Welding
Figure 27.17 Laser welding of razor

blades.
Flame Cutting and Drag Lines
Figure 27.18 (a) Flame cutting of steel plate with an oxyacetylene torch, and a cross-
section of the torch nozzle. (b) Cross-section of a flame-cut plate showing drag lines.

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CHAPTER 27

Figure 27.3 Schematic illustration of the pressure-gas welding process.

Figure 27.4 Schematic illustration of the shielded

Figure 27.5 Schematic illustration of the shielded

Figure 27.6 A deep weld showing

Figure 27.7 Schematic illustration of the submerged-arc welding process and

Figure 27.8 Schematic

Figure 27.9 Basic equipment

The next-to-last digit indicates position:

Figure 27.14 Equipment for gas tungsten-arc

Figure 27.15 Two types of plasma-arc welding processes: (a)

Figure 27.17 Laser welding of razor

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